3ES100_MDU.
-BEFORE STARTING an INSTALLATION, carefully read the SAFETY WARNINGS, THE WIRING NOTES AND THE INSTALLATION INSTRUCTIONS in this MANUAL .
- This apparatus must be installed in accordance with the requirements set forth in standard IEC - EN60204
- This apparatus must be installed carefully, by following the instructions provided in the THERMOSALD ISX-COPRO USER MANUAL and in the GENERAL USER MANUAL.
- This apparatus must be installed by skilled and properly trained personnel.
4.2 CHOOSING THE COMPONENTS AND TECHNICAL NOTES FOR INSTALLATION For the general notes, please refer to the basic user and maintenance manual 3ES100_MDU.
4.2.1 SECONDARY THERMOREGULATOR
For the general notes, please refer to the basic user and maintenance manual 3ES100_MDU.
4.2.2 POWER TRANSFORMER AND SIZING
For the general notes, please refer to the basic user and maintenance manual 3ES100_MDU.
4.2.3 SIZING THE PROTECTION DEVICES
For the general notes, please refer to the basic user and maintenance manual
4.2.6 WIRING INSTRUCTIONS
For the general notes, please refer to the basic user and maintenance manual 3ES100_MDU.
For the electrical connections, refer to the wiring diagrams provided as examples in chapter 4.3.
VERY IMPORTANT WIRING INSTRUCTIONS FOR SAFETY AND TEMPERATURE ACCURACY:
EMERGENCY BUTTON: The emergency button that stops the end machine will stop all machine operations connected to it, including the sealing operations, and will cut off power at once.
EMERGENCY CIRCUIT: the thermoregulator's ALARM output must cut off the thermoregulator's power directly, without going through the PLC, and warn the PLC about the triggered alarm (see example in wiring diagram in chapter 4.3).
POWER CABLES: these cables must be of the proper size and twisted (both the 2 input cables from the transformer to the thermoregulator, and the 2 output cables from the thermoregulator to the machine). Concerning bands that are not too short, you can use a supporting machine terminal block near the band, where you can connect the bands, the reference cable and the power cables from the thermoregulator. It is advisable to place the machine terminal block inside 1 standalone box for each thermoregulator so as not to bundle the wires of multiple thermoregulators, which would generate instability.
REFERENCE CABLES: use 1 shielded reference cable for each thermoregulator (connect thermoregulator input to machine terminal block near the bands, if provided).
WIRING OF OPPOSED BANDS: opposed bands cannot be connected in series but must be connected only in parallel, so that all opposed points will be at the same potential. In the case of parallel bands, make sure that it is not possible to mistakenly connect the bands in an anti-parallel manner even when bands will changed over time.
MOUNTING THE BANDS ON THE BAR: isolate the bands from the machine's mechanical structure. The ends of the bands must be copper-plated; this plating must cover at least 1 cm of the bar to avoid any overtemperatures in the zones up in the air between the bar and the terminal. Bands should bear in the same manner on all the bar's points to avoid any overtemperatures in the zones where bands do not bear on the bar.
TERMINALS: tighten all the terminals to their limit, especially the power terminals.
- Mechanically secure the thermoregulator to the plate through the fixing holes
- Connect the protective ground conductor to the fixing bolt, provided and identified by the PE yellow-green indication on the dissipator. The core section of the ground conductor should be
>= the power conductors . It is advisable to connect the ground conductor directly to the galvanized support plate as close as possible to the ground bolt.
4.2.7 INSTALLATION INSTRUCTIONS
For the general notes, please refer to the basic user and maintenance manual 3ES100_MDU.
Below are summarized any dangerous unpredictable faults that may occur, and how to solve them:
POWER SCR BREAKAGE: in order to avoid overheating, the thermoregulator opens the alarm contact instantly; this contact must cut off the emergency chain. We observed an increase in temperature of a few degrees during lab tests. Records on over 10,000 applications do not record any such event. It is advisable to carry out a machine simulation.
BAND BREAKAGE: the thermoregulator stops regulating and opens the emergency contact instantly. During lab tests we observed that a small spark may occur due to the waveform that has already triggered; to prevent breakage, it is advisable to use bands having a good-sized section, e.g.: 0.3 mm, and to change bands during scheduled maintenance to prevent wear.
BAND AND GROUND SHORT CIRCUIT: il termoregolatore blocca la regolazione e apre istantaneamente il contatto di emergenza. During lab tests we observed that a small spark may occur due to the waveform that was already triggered; to prevent short circuits, it is advisable to place and/or handle the bands so that there can be no accidental contact between the bands and the machine's metal structure (see chapter 4.2.6 wiring notes).
SHORT CIRCUIT BETWEEN BANDS: This event cannot occur if wiring is made correctly (see chapter 4.2.6 wiring notes).
BANDS NOT COPPER-PLATED AND NOT BEARING ON BARS: the thermoregulator regulates the band's average temperature with the same heating current: temperature increases in the air. This event cannot occur if the bands are copper-plated in the terminals' area and if they bear equally on the entire bar. Give the sealing command when grippers are closed or, even better, a few moments before the grippers close, so that temperature will be distributed evenly on the entire bar, from one copper-plating to the next.
BAND AGING: Temperature is measured by reading the band's electrical characteristics;
there is a change in the electrical characteristics of bands currently on the market, when used at temperatures higher than 180°, and the band's real temperature therefore changes by a few degrees. In particular, you can observe that the displayed balancing temperature decreases by a few degrees over time. You should not exceed 180° working degrees to guarantee a fairly stable temperature. It is advisable to choose stable, properly copper-plated bands, and to check temperature behaviour in the machine to see if the
temperature error is acceptable. Replace the bands according to scheduled maintenance and machine requirements.
Below are summarized the inspections to be carried out and relating conditions:
TEMPERATURE COEFFICIENT of installed bands: the band's TEMPERATURE COEFFICIENT, declared in PPM or parts per million, must be equal to machine TEMPERATURE COEFFICIENT data.
TEMPERATURE PROBES: In order to have an accurate balancing temperature, you can mount the TEMPERATURE PROBES on the sealing bar or near the band in order to measure the band's temperature during calibration (see order-placing data in chapter 8).
CALIBRATION WHILE MACHINE IS COLD: calibration must be carried out when machine temperature is cold and stable to allow the band to be very close to the room temperature set in machine CALIBRATION TEMPERATURE data or, if the TEMPERATURE PROBE is present, it should be very close to the probe's temperature.
MAXIMUM WORKING TEMPERATURE: If the band must not exceed the preset maximum temperature for working purposes, set the MAXIMUM TEMPERATURE internal parameter.
Whereas if the band must not exceed a preset maximum temperature for safety reasons, you can purchase the preset TEMPERATURE COEFFICIENT and MAX REQUIRED TEMPERATURE options (see order-placing data in chapter 8).
TEMPERATURE ACCURACY: the thermoregulator features the degree resolution but the real temperature at all the band's points depends on some factors already described elsewhere, which we have summarized here: correct temperature coefficient, correct balancing temperature, calibration while machine is cold, use of temperature probes, band with good copper-plating at the ends, good contacts, exactly parallel bands, bands bearing evenly on the entire bar, working temperature not higher than 180° C, band replacement before it ages.
ALARM OUTPUT CONTACT TEST AND EMERGENCY CHAIN CHECK: the thermoregulator features an alarm output contact, CN6/6-7, which opens at any of its alarm conditions and that must consequently open the emergency chain: in order to check its working efficiency, press the mode button as is done at power-on, or access the emergency control menu: the alarm output relay must open, and consequently the power circuit must open and remain off. Should any chain component be faulty, the thermoregulator triggers alarm 79.
WORKING CONDITION CHECK: it is advisable to install an ammeter on the current circuit, which can be seen by the operator to check the machine's proper operation.
- Do not enable the thermoregulator's power circuit when the machine's mechanical guards are open.
- Do not power-on the thermoregulator without its safety cover.
- Install all the bands to ensure perfect contact; use copper-plated bands locked on firm terminals and/or eyelets, or terminals+eyelets. The copper plating should cover the band by a few millimeters outside the bag up to the far ends inside the terminal.